AdvantagesOf CLC Blocks
- Light in Weight : CLC blocks are very lightweight with density ranging from 300 to 1800 Kg/m3. Three times less weight then clay or fly ash brocks.
- Eco friendly : CLC blocks are Environment-friendly. Foam concrete is eco- friendly material as fly ash and other industrial waste material are used in part of manufacturing blocks to protect the environment. The production process of CLC or its use does not release any harmful effluents to ground, water or air. CLC, due to its low weight is ideal for making partitions. The use of CLC for this purpose will reduce the need for plywood partitions. This consequently will result in reduction in deforestation and will benefit environment.
- Sound Insulation : CLC Blocks are excellent for Sound insulation which keeps the house cool in Summer and warm in Winter saving energy/electricity for cooling and heating. It is possible to achieve even higher values depending upon the thickness of block.
- Thermal Insulation : Thermal insulations as a 100mm thick CLC wall, the equivalent thickness of dense concrete wall would have to be more than 5 times thicker and ten times heavier.
- Lower Water Absorption : The water absorption of this material in relatively lower than any other materials. This compares much better than concrete 50% and ordinary brick, which has water absorption of around 50% to 80%. The low water absorption property of these blocks will help to reduce the cracks in the walls.
- Fire Protection : Foam concrete blocks offers grate fire protection. With a just 100mm thickness of wall with density of 1000 kg/m3, offers fire endurance for heat transmission for 4 hours without releasing any oxic fumes during the fire. Fire rating of cellular concrete is far superior to that of brickwork or dense concrete.
- Easy to Handling : Foam concrete blocks are easy and quick to install, thus minimizing construction costs. They require no minimal maintenance, which reduces long- term costs. Foam concrete blocks are saving in cement, sand, water, labour, energy & time
Cost Effective Material
CLC Bricks are the most popular construction material in India and all across the globe. They are also known as Light Weight Bricks that help in building all types of infrastructures, including small, medium and huge. They are cost effective and also save several days in construction.
Procedure of Making CLC
Aqueous foam is produced from the foam generators (IFG) and injected into slurry of cement, fly ash and water in foam concrete mixture (IFM). It creates many small air cells which are uniformly distributed throughout the concrete and create cellular from 300kg/m3 to 1800kg/m3 with compressive strength between 5kg/cm2 to 200kg/cm2. The volume of air cells in foam concrete determines the density and strength. The final mixture is then used for different applications without any vibration or compaction. Fly ash which is a waste-product at thermal power stations. The foam concrete is thus a green building material.
House made of Lightweight Concrete Blocks
Cellular Lightweight Concrete (CLC) is conventional concrete, where natural aggregate (gravel) is exchanged for the best insulation medium available, namely air, embedded in an organic and bio-degradable foam that offers no chemical reaction but solely serves as wrapping material for the air. Consequently CLC behaves, like conventional concrete, in particular concerning curing, hardening and most important “ageing “. CLC infinitely increases its strength by hydration (forming of crystals in cement) as long as exposed to humidity in the atmosphere. For structural (steel-reinforced) application, CLC is used in densities of 1,200 to 1,400 kg/m³, which, due to the billion of micro-sized and uniform air bubbles offer 500 % more thermal insulation and a substantially higher fire-rating than conventional concrete. If a wall of conventional concrete should offer the same thermal insulation as CLC, the wall produced would have to measure 5 times thicker and therefore also use 10 times more material (sand, gravel, cement) to produce. CLC structures in hot climatic zones require only 1/5th energy for air-conditioning when compared to traditional clay-brick structures. Since the early twentieth century, two ideas were developed to produce lightweight concrete – Aerated Autoclave Concrete (AAC) and Cellular Lightweight Concrete (CLC). Each is based on the idea that adding air bubbles to mortar would lower its weight while at the same time improving the product. The difference between AAC and CLC lies in how the air bubbles are generated. AAC uses aluminum powder to catalyze a reaction that generates hydrogen gas – bubbles formed from the reaction and are trapped in a lime, flyash, gypsum and very small percentage of cement slurry. The slurry is allowed to set and then the product is cut into panels or blocks and placed in an autoclave to cure (an autoclave is required because the slurry has low cement contents). CLC is a process based on making air bubbles in the form of a foam and then mixing the foam into a cement / flyash slurry. The slurry is then poured into moulds. Since CLC slurries have higher cement contents, no autoclave curing is required – instead, the finished product is cured like normal concrete or Steamed Cured with low pressure to achieve early strength. As compared to AAC lightweight products, CLC air bubbles are significantly smaller, stronger, and each bubble is part of a closed cell system – which means Brickwell CLC block products have lower water absorption – about half of the water absorption as AAC And Brick. Like Cement, CLC blocks increase in strength when exposed to moisture. Hence CLC bricks become tougher over time.